USER MANUAL

TFP-Series

ACTIVE POWER CONTROLLER

Ver_2005 2014.02

Mark Name Explanation

Notice for electric shock

This symbol marks the parts where there is danger of electric shock. Power must be turned off for maintenance or repair of the product.

Notice

Warning Danger

This symbol indicates risk of death or serious injury. When the product is used incorrectly, it could cause property damage.

Grounding

To prevent malfunction, you must operate grounding To prevent electric shock or noise from the outside.

About Products Services

* Term of guarantee of this product is 1 year from the purchase date.

Charged Services

-Please read the manual in advance, as a service charge will be imposed for any service request on a product without defects.

When a defect occurs due to mishandling or improper repair.

• A defect because a user doesn’t follow the instructions in the manual. • A defect caused by not following rating, current capacity, or using abnormal voltage or power. • A defect caused by using components that our company doesn’t designate. • A defect caused by repair work of non-specialists. • Alternation of fuse and consumption goods. • A defect caused by natural calamities.

Symbol explanation

Product installation environments

- Install this product vertically to activate ventilation and do not use it in or around flammable, explosive, corrosive, and humid environments.

Notices for safety

1. Before installing this machine, install main power circuit breaker (NFB) and Magnetic switch an the outside of the main body for safety. 2. Ground type 1 grounding or special type 3 grounding in the exterior box of the machine to prevent electric shock. 3. Check that voltage of provided power is same as the voltage of the machine and the rated current is not exceeding proper capacity of load current. Then, provide the power. (It is recommended that you do not use a machine at over 70% of the rated current condition.) 4. Fuse 1) To prevent fire and to protect the machine, use a fast-acting fuse,which is designated by our company. (Refer to the product label) 2) Must turn off the main power to exchange the fuse. 5. Environments 1) Adjust ventilation and temperature so that temperature inside the control panel is not over 45˚C. 2) Do not operate the machine where there is a risk of inflammability, explosiveness, corrosion or humidity. 6. Disassembly or remodeling of the machine 1) Never change components voluntarily with the exception of changes of fuse or thyristor. 2) Our company can not guarantee operation of the machine when the volume of the machine or component is altered voluntarily. When a problem occurres, please contact our company’s A/S Department. 7. Check and repair 1) Before checking the machine, cut off the power and beware of electric shock. 2) Check fastening condition of bolts and nuts of terminal parts. 3) When bolts of terminal are loose, it could generate heat so wiring can be damaged or fire can occur. Check this condition periodically. 8. This manual could be revised without notification for improvements of functions of the machine. 9. Responsibilities and guarantee 1) Must preserve notices for handling, maintenance, and repair of the machine. 2) Our company is not responsible for damage, which occurs due to not following these instructions.. 10. A/S Request A/S Department TEL 82-53-355-3621 FAX 82-53-957-3622 mail :csm-korea@hanmail.net http://www.csmkorea.com

Must preserve notices during handling the machine to ensure safety.

SERIAL NUMBER LABELS

An identification label(specifying the coding of the thyristor unit) provide all the information relating to the factory settings of the thyristor unit.

Figure 1 Example of identification label for a TFP3-110 -P thyristor unit

Must preserve notices during handling the machine to ensure safety.

Figure 2 Example of identification label for a TFP3-110-Z thyristor unit

Fuse : HINODE 660GH-125A Any other fuse invalidates warranty

E.S.T , Republic of Korea +(82) 053 – 355 - 3621

Product : Power Regulator Model : TFP3-110-P Serial No : 110311-01-083-PY3HA1 Power Rating : 110A / 380V 50/60Hz

mail : csm-korea@hanmail.net A/S (053) 355 - 3621

Input : 4~20mA. 1~5V. 0~5V. 0~10V Firing Mode : PHASE ANGLE

Fuse : HINODE 660GH-125A Any other fuse invalidates warranty

E.S.T , Republic of Korea +(82) 053 – 355 - 3621

Product : Power Regulator Model : TFP3-110-Z Serial No : 110311-01-083-PY3HA1 Power Rating : 110A / 380V 50/60Hz

mail : csm-kores@hanmail.net A/S (053) 355 - 3621

Input : 4~20mA. 1~5V. 0~5V. 0~10V Firing Mode : PHASE ANGLE

CONTENTS

PAGE

1. Identifying Label -------------------------------------- 6

1-1. Coding

2. INFORMATION 2-1. Front Panel 2-2 Mode select on the PCB Information

-------------------------------------- 7

3. Product Explanation -------------------------------------- 9

3-1. Technical Data

3-2. Cabling

3-3. Signal terminal arrangement and control input wiring method

3-4. System Block Diagram

3-5. Dimensions

4. Operation -------------------------------------- 16

4-1. Notices during operation

4-2. Automatic mode

4-3. Manual mode 4-4-1. L.E.D & ALARM information 4-4-2. L.E.D & ALARM information

5. Repair -------------------------------------- 20

6. Inspection -------------------------------------- 21

1 Identification

1-1. CODING

Note • The identifying label is located on the right side of the Power Regulator. • Please make sure that the Power Regulator is the same model as you ordered using the identification label and the code above.

① PHASE : S - Single Phase

T - Three Phase

② Model Type : N – Normal Type

F – FND Type

FP – FND Type Premium ( CE )

③ Input Voltage : 1 – 110V

2 – 220V

3 – 380V

4 – 440V

6 – 690V

④ AMP. : 25 ~ 1000 [A]

⑤ MODE & Option : P – PHASE ANGLE

Z – ZERO CROSSING

T F P 3 - 1 1 0 - P ① ② ③ ④ ⑤

2 INFORMATION

PHASE AMP.

①

②

③

Lamp signal

Lamp Signal

① OUTPUT (Output adjustment) : 0~100%, the maximum output setting volume ② SOFT (Soft up & down) : Soft start ( 0~10sec/60hz ) ③ O.C (Over current) : Over current limit setting volume

Lamp Operation condition

PILOT PILOT LAMP

Green light is flickering every 0.5 second.

OC OVER CURRENT (80%)

Alarm : Red light is turned on.

OT OVER TEMPERATURE

Alarm : Red light is turned on. (3-1-2)-⑥)

UL UNLOAD

Alarm : Red light is turned on.

LU LOAD UNBALANCE (70%)

Alarm : Red light is turned on.

SF SCR & FUSE FAULT

Alarm : Red light is turned on.

2-1 Front Panel

2 INFORMATION

▷ SW5 : Potentio meter select

Internal potentio meter (10KΩ) select

External potentio meter (10KΩ) select REMOTE CONTROL

▷ SW4 : Operation mode select

Automatic operation select Manual operation select

▷ SW3 : RUN / STOP Use when the liver diagnoses or power controller test !!!

Test running (RUN) The control is impossible to an external of contact.

STOP When Normal operation mode

SW5 SW4 SW3 RESET

2-2 Mode select on the PCB Information

3 Product Explanation (Phase angle)

3-1. Technical data( Phase Angle)

1) Operating Condition 2) Supporting functions ① Detect fuse disconnection, SCR short circuit, load short circuit. ② load disconnection alarm ③ Soft Start ( 0~10 sec/60Hz) ④ Remote control function (RUN) ⑤ Built-in the WDT(Watch Dog Timer) ⑥ Overheating prevention function (OT)

* Over 85˚C: Cut off the main power . ⑦ The maximum output adjustment. ⑧ Voltage/current/power Feedback (Option)

Model name TFP□-□□□-P

Control method Phase-Angel

Voltage (V) 220 V, 380 V, 440 V, 690V (Allowable tolerance ±10%)

Input signal 4~20 mA, 1~5 V, 0~5 V, 0~10V

Applied load Transformer coupled load or Resistance load

Rated frequency 50/60 Hz

Cooling method Natural convection below 30A model, fan cooling for over 40A

Possible operation temperature range

0 ˚C ~ 50 ˚C

Insulation resistance Over DC 500 V 200MΩ between power terminal and case

TEMP. PILOT OT

Below 70˚C ON (Green) OFF

Over 85˚C ON (Red)

3 Product Explanation 3-2. Cabling

A) 3 Phase (all models)

R , S , T – Line-side cabling U , V, W - Load-side cabling

R S T

U V W

Temperature Controller

Heater

Power Line

Temperature Sensor

+ -

+ -

Check that voltage of provided power is same as the voltage of the machine and the rated current is not exceeding proper capacity of load current. Then, provide the power. (It is recommended that you do not use a machine at over 70% of the rated current condition.)

3 Product Explanation

3-3. Signal terminal arrangement and control input wiring method

1) Control Input Terminal

Note

FG

+

-

Shield cable usage example

1. The main power must be cut off to connect wires. 2. To prevent malfunctions by noise, use the twist shield cable for control input wiring. FIELD GROUND and SIGNAL GROUND must be operated.

3. Install wiring of the control input part far from the other power lines.

Please refer to the control input wiring diagram, which is attached to the inside of the front panel, to connect the wires.

Danger,Warning : This symbol is displayed when there is risk of death or severe injuries. Notice : This symbol is displayed when there is a risk of property damage.

Danger,Warning/Notice

3 Product Explanation

3-3. Signal terminal arrangement and control input wiring method

2) Wiring-1

1) AUTO MODE ( 4 - 20mA )

2) Manual Mode

3 Product Explanation

3-3. Signal terminal arrangement and control input wiring method

3) Wiring-2

3) ALARM SET

2) OPTION SET

3 Product Explanation

3-4. System Block Diagram

1) Three Phase

Control Signal 4 ~ 20 mA

220V, 380V,440V,690V/60Hz

AUTO/MANUAL

EXT.POTENTIO-METER(10K)

ALARM

RUN/STOP

Heater Temperature

Controller

U FG

R

DC Power

Current Sensor

Controller

Fuses

V

S

W

T

PCB POWER AC220V

controll power terminal block The fan or power supply of 220V AC must be connected.

3 Product Explanation

3-5. Dimension

1) Three Phase

* Dimensions of the upper product could be changed without notification for improving functions.

TYPE 용량(A) H H1 W W1 D Weight (Kg)

Attachment screws

TFP 30,40,55,70 235 190 155 140 200 5.7 M5

TFP 90,110 300 286 173 130 230 9 M5

TFP 130,160 395 381 173 130 240 13 M5

TFP 200 415 397 262 200 255 18 M5

TFP 250,300 456 440 262 200 295 20 M5

TFP 400,500,600 550 532 330 280 310 28 M6

THREE PHASE ( TFP TYPE )

HH1

WW1 D

H

WW1

H1

D

TFP Type TFP Type

4 Operation

4-1. Notices during operation

1) Don’t be close to the power terminal part of the machine. There is a risk of electric shock. 2) Some parts of the inside of the machine are hot. Do not put your fingers near the cooling fan. The fan rotates at high speed and could cause severe injuries or defects in the machine. 3) Be careful of no-load operation. Don’t provide the power at no-load condition because it could occur over voltage, which could break the transformer.

4-2. Automatic mode

1) Connect “+ ” of 4~20mA input signal (1~5V input signal) to the No.1 terminal of ‘CONNECTIONS’ terminal block (shown below) and “-” to the No. 2 terminal. Then, connect the No.7 & 8 or No.8 & 9 terminals together using a wire. 2) To limit max. power output, set the ①OUTPUT volume properly. 3) Set the ③O.C volume. (Usually set to 10% more than normal load condition. 4) Set the ②SOFT volume, if needed, according to the load condition (0~4sec/60Hz).

Danger,Warning: This symbol is displayed when there is risk of death or serious injury. Notice: When the product is used incorrectly, it could cause [property damage. This symbol is displayed on the parts where electric shock could occur. power must be turned for maintenance or repair of the product.

Electric shock, Danger, Warning/ Notice

4 Operation

Danger,Warning: This symbol is displayed when there is risk of death or serious injury. Notice: When the product is used incorrectly, it could cause [property damage. This symbol is displayed on the parts where electric shock could occur. power must be turned for maintenance or repair of the product.

Electric shock, Danger, Warning/ Notice

4-3. Manual operation

1) When an external volume is used (recommend a 10kΩ potentiometer) A) Short (Turn ON) the No. 6 & 7 terminals together by using a wire. B) Connect a 10kΩ potentiometer at the No. 3,4, & 5 terminals and fix firmly. Then, output power will be controlled by the settings of the potentiometer. C) To limit max. power output, set the ①OUTPUT volume properly. D) Set the ③O.C volume. (Usually set to 10% more than normal load condition) E) Set the ②SOFT volume, if needed, according to the load condition. (0~4sec/60Hz)

2) When an internal volume is used (use ‘OUTPUT’ volume of the front panel) A) Set the ①OUTPUT volume of the front panel as the minimum value. B) Connect (Turn ON) the No. 4 & 5 terminals together using a wire. C) Connect (Turn ON) the No. 6 & 7 terminals together using a wire. D) To set output power, set the ①OUTPUT volume properly. E) Set the ③O.C volume. (Usually set to 10% more than normal load condition) F) Set the ②SOFT volume, if needed, according to the load condition. ( 0~4sec/60Hz)

1) PILOT LED : Green color

* Running : Over a control output value 0 %, lighting hold Control output value 0 %, lighting off * Stop : Lighting off * Input signal error (4-20mA) : 1 second cycle lighting blink * P.W value 0 % : 2 second cycle lighting blink

• PHASE : 3 color L.E.D, Nominal current (per phase) index of an each load. RED : R-Phase, Yellow : S-Phase, Green : T-Phase White : Average nominal current value

• MODE : Small type push button switch, selectable load phase for display on the FND.

4 Operation

4-4-1. L.E.D & ALARM information

2) OVER CURRENT LED : Red color

- White : Normal running condition

- Lighting : Over-current trip is peak current sensing ① Power controller make the stopping ② Alarm relay output ③ The color appeared peak current sensing phase. ④ Over current value display on the FND. - Factor ① At the loads caused by a short between phase ② An earth between the phase and case. ③ An electromagnetic interference and to happen.

3) OVER TEMPERATURE : Red color

- White : Normal running condition - Lighting : A heat sink surface temperature is over the 85℃ ① Power controller make the stopping ② Alarm relay output - Factor ① Cooling fan defect ② Ambient temperature is over the 40℃ Attention! The units are designed to be used at an ambient temperature less than or equal to 40°C. Leave a minimum gap of 5cm between two units placed side by side. Excessive overheating of the controller may lead to incorrect operation of the unit. This may in turn cause damage to the components.

- Restart : Necessarily examine an over current reason closely and after make “RESET”.

6) SCR FAULT : Red color

- White : Normal running condition - Lighting : A current detection in a stopping condition, sell to SCR short fault. ① Power controller make the stopping ② Alarm relay output ③ The color appeared peak current sensing phase. ④ The load current value display on the FND. - Factor ① The heat element at short. ② The parallel SCR case which one becomes the breaking among two. ③ The C.T (current transformer) defect

4) UNLOAD LED : Red color

- White : Normal running condition - Blinking : Unload (heat element be cut or at short) sensing and during the make an analysis about 10 second. - Lighting : Unload determination ① Alarm relay output ② The color appeared unload sensing phase. ③ The FND value becomes ‘0’. - Factor ① The heat element be cut. ② The heat element at short. ③ The fuse be cut or defect of the SCR.

② The color appeared sensing of the unbalance load phase. ③ The load current value display on the FND. - Factor ① The heating element case which one becomes the breaking among many. ② The C.T (current transformer) defect ③ The defect one among a parallel SCR.

5) UNBALANCE LOAD LED : Red color, Optional function. - White : Normal running condition - Blinking : The sensing load current value of an each line-to-line the declination over the 30%, during the make an analysis about 10 second. - Lighting : Unbalance determination ① Alarm relay output

4 Operation

4-4-2. L.E.D & ALARM information

7) How to reset ① Necessarily examine an over current reason closely and after make “RESET”. ② Press the reset button

③ Please mains power OFF AND ON

5 Repair

. The main power must be turned off to change the fuse.

. A fuse designated by our company must be used.

. Check that the fuse is fastened correctly after it is changed.

FUSE Exchange

. The main power must be turned off to change the SCR element.

. An SRC designated by our company must be used.

. Check that the SCR is fastened correctly after changing it.

SCR Exchange

. The main power must be turned off to check PCB UNIT.

. PCB UNIT is manufactured through our company’s precise inspections. When a problem occurs in the PCB UNIT, please contact our company’s A/S Department.

PCB UNIT

Danger,Warning: This symbol is displayed when there is risk of death or serious injury. Notice: When the product is used incorrectly, it could cause property damage.

Danger, Warning/ Notice

6 Inspection

Danger,Warning: This symbol is displayed when there is risk of death or serious injury. Notice: When the product is used incorrectly, it could cause property damage.

Danger, Warning/ Notice

. The main power must be turned off to operate periodic inspection. There is a risk of defect, electric shock, or fire.

Periodic Inspection

Please operate the periodic inspection, the following items, once every 6 months to maintain the best condition and functions of the machine.

1. Cleaning Dust may come from the outside. When there is dust, such as iron powder, insulation is

worse and causes inferiority of operation. So please clean the attached materials. Remove the dust, on the components, using a soft brush or air. 2. Components fastening condition Check the screw fastening condition of each connection part. The screw could be

loosened with time. Fastened screw could cause damage by heat so it could cause control instability or

defects. So periodic inspection is necessary to keep the normal condition. 3. Wiring condition check Must check abnormality or modification of insulating covering of input and output wires

of the machine. When there is abnormality, please change the part. 4. Other check items

Must check the fastening and connection condition of connector and terminals in the machine.

7 MEMO

7 MEMO

#103 The second pilot production plant ,GyeongbukTechnopark,

27, Sampung-ro, Gyeongsan-si, Gyeongsangbuk-do, Korea

TEL : +82-53-355-3621 A/S : +82-10-3749-9074

FAX : +82-53-957-3622

mail : csm-korea@hanmail.net www.csmkorea.com